Brake Caliper Piston Seal Dynamics for Wear Reduction
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Solution Overview
Problem
Current automotive brake designs experience poor brake pedal feel and increased wear due to the friction material maintaining slight contact with the rotating surface when not in use, leading to reduced fuel economy and irregular wear patterns.
Innovation Solution
A brake system that controls the friction material to engage and disengage with the rotor based on input from a sensor and brake control system, allowing for a ready-to-engage state to minimize unnecessary contact and wear, utilizing a caliper and piston seal configuration that adjusts to maintain optimal engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the friction material maintains slight contact with the rotor when not braking, then the brake pedal feel is improved, but fuel economy is reduced and wear increases
Solution Approach 1:
The brake system dynamically adjusts the friction material position between two states: slight contact during non-braking conditions for good pedal feel, and complete disengagement for fuel economy. The control system monitors brake application status and automatically transitions the friction material between these states, making the system adaptive rather than static.
Solution Approach 2:
The system changes the positional parameter of the friction material relative to the rotor based on operating conditions. When braking is not applied, the friction material is positioned to maintain slight contact (parameter state 1). When braking is detected via sensor input, the system transitions to a different parameter state where the friction material is fully engaged. This parameter change resolves the contradiction by optimizing for different priorities at different times.
2Ease of operation
If the friction material maintains slight contact with the rotor when not braking, then the brake pedal feel is improved, but wear on components increases
Solution Approach 1:
The system dynamically switches between two operational modes: a standby mode with slight friction material contact for good pedal feel, and an active mode with full engagement for braking. The control system detects brake application status and transitions between modes, minimizing unnecessary wear while preserving pedal feel quality.
Solution Approach 2:
The friction material's positional parameter is changed based on brake application detection. In the non-braking state, the parameter is set for slight contact to maintain pedal feel. When the sensor detects brake input, the parameter changes to full engagement, reducing wear during non-braking periods while maintaining operational quality.
3Loss of substance
If an air gap is left between the brake pad and rotor, then wear is reduced, but brake pedal feel becomes poor and response is delayed
Solution Approach 1:
The system dynamically positions the friction material in two distinct states: a ready state with minimal gap for immediate response and good pedal feel, and a disengaged state with larger gap for wear reduction. The control system monitors for brake input and transitions between these dynamic states, optimizing both wear and response characteristics.
Solution Approach 2:
The gap parameter between friction material and rotor is changed based on detected brake input. When no braking is detected, the system maintains a larger gap to reduce wear. When brake input is detected, the parameter changes to minimize the gap, ensuring immediate response and good pedal feel without requiring the driver to compensate for delay.
4Speed
If the friction material maintains slight contact with the rotor, then brake responsiveness is improved, but irregular wear patterns occur due to rotor run-out
Solution Approach 1:
The system dynamically adjusts friction material engagement based on detected brake input. During non-braking conditions, the friction material is disengaged or minimally contacted, preventing irregular wear from rotor run-out. When braking is detected, the system quickly transitions to full engagement, ensuring rapid response. This dynamic approach decouples wear prevention from response speed requirements.
Solution Approach 2:
The engagement parameter of the friction material is changed based on brake input detection. In the non-braking state, the parameter is set to disengage or minimize contact, preventing irregular wear patterns caused by rotor run-out. When brake input is detected, the parameter changes to full engagement, ensuring immediate brake response. This parameter switching resolves the contradiction by addressing wear and response at different times.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Improves brake pedal feel and reduces wear by minimizing friction material contact with the rotor during non-braking conditions, enhancing fuel efficiency and preventing irregular wear patterns.
Implementation Method 1
the piston seal returning to its non-deformed shape (called 'rollback')
Implementation Method 2
force a friction material against a rotating surface of the brake when the brake is applied
Data Source
AI summary
Methods and apparatus for braking may control a brake between three states. Methods and apparatus for braking may comprise a sensor for sensing information about a brake input device, may comprise a brake control system coupled with the brake and the brake input device, and may control the brake based on the sensed information and input to the brake input device. Methods and apparatus for braking may control the brake to engage a friction material with a rotor if the brake input device indicates the brake should be engaged, and to remove the friction material from contact with the rotor if the brake input device indicates the brake should not be engaged. Methods and apparatus for braking may determine a condition of imminent braking based on the sensed information and may control the brake to enter a ready-to-engage state accordingly.